optimized spool gun procedures for aluminum

[old jupiter]

Been watching this with interest, since I rarely use my spool gun, and need any pointers I can pick up. Bob, this is NOT, repeat NOT, to argue with someone (You) with substantial experience, but do you understand about all the raised eyebrows at your ".030" tip for .035" wire" suggestion? Presumably the others, like me, have seen more than one printed recommendation to use one-size-OVER tip with aluminum because it expands more than steel when it gets hot. Bob, I'm certainly not trying to get you to hedge your advice, or make you repeat it endlessly, LOL. I just feel that with interesting experiences like yours, you might have come up with some ideas as to why your findings are opposite to other advice we're getting. In any case, I'm going to do my own little tip-size tests next time I run the gun (though I don't look forward to having to clear birdnests from my Traffimet!).

Oscar mentions tolerances, and I understand that one issue people are having with Chinese welding wires (which I don't buy) (so far as I know) is that they often don't hold wire diameter to acceptably tight tolerances. This is also true of contact tips, and unfortunately it's not easy, maybe not possible, to know where these were made. Maybe some of the problems that occasional users have with their spoolguns are coming from this cause. Maybe I should be hand -feeding tip-drills down every contact tip to affirm actual diameter . . . ??

[aametalmaster]

Glad it worked out for you guys...Bob

[OscarJr]

After bird nesting my Millermatic 100 spool gun 25 times trying to weld .035 wire with a .030" tip I was about to list on eBay. I finally bought some .035" tips and didn't bird nest or ruin a tip in 2 hours working with the gun. Probably 40 minutes of welding. In summary if you use .035 wire use .035 tips.

Yup, I've used the appropriate size tips in my spoolmate150 and didn't have any issues, thankfully.

[Mathew530]

After bird nesting my Millermatic 100 spool gun 25 times trying to weld .035 wire with a .030" tip I was about to list on eBay. I finally bought some .035" tips and didn't bird nest or ruin a tip in 2 hours working with the gun. Probably 40 minutes of welding. In summary if you use .035 wire use .035 tips.

[aametalmaster]

Most tips are .010 -.014 bigger than whats stamped on them...Bob

[OscarJr]

Okay, now I'm more confused. How does 0.035 wire fit through a 0.030 orifice?

Things are not exact. Likely due to tolerances in the tip orifice, maybe even the wire itself.

To the OP, have you calibrated your spoolgun?

[Goodhand]

Yup thats what i use. I quit buying .035 tips and use .030 for all of my wires for any wire .030 or .035...Bob

Okay, now I'm more confused. How does 0.035 wire fit through a 0.030 orifice?

[ryanjones2150]

there ya go, use what the guy that knows uses. If it works, that's all that matters!

[Mathew530]

Thanks Bob!!!!!!!!!!

[aametalmaster]

I believe AAmetalmaster recommended the .030 tip with the .035 wire. I know it sounds backwards, maybe he will chime in. There is another post which says the smaller tip gives better control. I appreciate the response and it is why I asked.

Yup thats what i use. I quit buying .035 tips and use .030 for all of my wires for any wire .030 or .035...Bob

[ryanjones2150]

I've always used a tip a size up from my wire size. But then again, I don't have a spool gun, just run 3/64 5356 through my MM250 with success.

[Mathew530]

I believe AAmetalmaster recommended the .030 tip with the .035 wire. I know it sounds backwards, maybe he will chime in. There is another post which says the smaller tip gives better control. I appreciate the response and it is why I asked.

[nfinch86]

Performed AAMetalmaster mod on the nozzle, to cool to give such a detailed write-up. I have to admit I impressed myself with my POS drill press. Am i correct the optimism set up for the 100 is .035 wire with a .030 tip? Also how critical is the length of the inner liner "spring" should it be compressed by the tip when screwed in? Looks like I will need to trim mine about 1/4". What keep it from falling out when you change tips? Thanks for the help!!!!

Wrong - That's a .035" Tip , with .030" wire, Not the other way around !

Norm

[Mathew530]

Performed AAMetalmaster mod on the nozzle, to cool to give such a detailed write-up. I have to admit I impressed myself with my POS drill press. Am i correct the optimism set up for the 100 is .035 wire with a .030 tip? Also how critical is the length of the inner liner "spring" should it be compressed by the tip when screwed in? Looks like I will need to trim mine about 1/4". What keep it from falling out when you change tips? Thanks for the help!!!!

[Mathew530]

Performed AAMetalmaster mod on the nozzle, to cool to give such a detailed write-up. I have to admit I impressed myself with my POS drill press. Am i correct the optimism set up for the 100 is .035 wire with a .030 tip? Also how critical is the length of the inner liner "spring" should it be compressed by the tip when screwed in? Looks like I will need to trim mine about 1/4". What keep it from falling out when you change tips? Thanks for the help!!!!